Handle with soft gel cushioning member

ABSTRACT

The handle construction of the present invention includes a low durometer grip portion that provides comfort and an ergonomic benefit to the user. The handle includes a rigid core with a gel member received in a recessed seat. The gel member preferably has a durometer of 65 Shore 00 or less. A thin top finish layer, of elastomeric or polymer film, is optionally provided on the top of the gel member, such as in a thickness of less than 4 thousandths of an inch in thickness (&lt;4 mil) to provide a durable and aesthetic surface. The combination of the molded low durometer gel member, with an otherwise rigid handle, allows for the creation of an overall handle that has areas that are more rigid along with areas that exhibit a very soft feel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to and claims priority from earlier filedprovisional patent application Ser. No. 60/753,871, filed Dec. 23, 2005.

BACKGROUND OF THE INVENTION

This invention relates generally to an innovative handle construction,that can be used on an implement or tool, such as for a toothbrush orrazor. There are many different types of tools, implements and objects,such as razors and toothbrushes, that require fairly precise handlingand yet both also benefit from having a soft feel for the user whilehandling.

In the prior art, by way of example, there are various razors ortoothbrushes that are made of rigid plastic or metal and are thus hardto the touch. There have also been many attempts to make razors andtoothbrushes that are more comfortable for human contact, such as by thehands and fingers. The entire razor or toothbrush does not need to besoft; rather it is desirable for much of these handles to be rigid sothey are easy to control. It is generally thought to be desirable forthe areas in contact with the fingers to be soft so as to lesson thepressure on the fingers. For this reason, prior art razors, toothbrushesand other tools and implements have been made with areas of softermaterials. Because very low durometer gels are generally very sticky tothe touch and have other undesirable surface characteristics, most ofwhat are considered low durometer materials that are used in prior artrazor and toothbrush handles are of a 50 shore A hardness or above.

In the prior art, in order to get the finished molded razor handlesofter, for example, these 50 shore A or similar durometer plastics areoften molded into shapes with thin “fins”. These thin fins can behavelike a softer material, because the plastic will bend more easily atthin gauge. In this way, the prior art has attempted to createtoothbrush and razor handles that have areas that are as soft aspossible and yet durable.

There have also been examples in the prior art of the use ofthermoplastic elastomers with durometers as low as 70 shore 00 hardnessin toothbrush handles. TPE's in this hardness range have been used assome can be made to have acceptable surface characteristics anddurability, and have not necessitated a film surface or polymer topfinish coat.

In view of the foregoing problems associated with the prior art, thereis a need for handles with significantly softer materials than are foundin any of the prior art, such that the touch points will conform morereadily to the pressure of the fingertips. There is a need for a handleconstruction, for use on razor, toothbrushes, and that like, that ismore comfortable than those existing in the prior art. There is a needfor a handle that incorporates three dimensional molded gel of less than65 shore 00, and a top surface layer of elastomeric film or anelastomeric polymer surface coating.

SUMMARY OF THE INVENTION

The present invention preserves the advantages of prior handles withcushioning elements therein. In addition, it provides new advantages notfound in currently available cushioned handle constructions andovercomes many disadvantages of such currently available handleconstructions.

The handle construction of the present invention includes a lowdurometer grip portion that provides comfort and an ergonomic benefit tothe user. More specifically, the present invention relates to handles orany gripping surfaces or areas, such as for a toothbrush or razor, witha grip with both rigid areas and areas containing three-dimensionalmolded gel with a durometer of less than 65 shore 00. The grip areaswith three dimensional molded low durometer gel also then have a thintop layer of elastomeric film of less than 4 thousandths of an inch inthickness (<4 mil) to provide a durable and aesthetic surface, orinstead of the film they have an elastomeric polymer top-coating. Thecombination of the molded low durometer gel “medallions”, with anotherwise rigid grip, allows for the creation of a grip that has areasthat are more rigid along with areas that exhibit a very soft feel. Thethickness of the gel does not need to be uniform, but can be thicker inareas where such is advantageous or aesthetically pleasing to the user.

It is therefore an object of the present invention to provide a superiorhandle construction that is soft to the touch to the user in theappropriate locations.

There is a further object of the present invention to provide a handleconstruction that incorporates three dimensional gel material forsuperior comfort and control for the user.

There is also an object of the present invention to provide a handleconstruction that complements a rigid core to combine comfort andcontrol in the same handle.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features which are characteristic of the present invention areset forth in the appended claims. However, the invention's preferredembodiments, together with further objects and attendant advantages,will be best understood by reference to the following detaileddescription taken in connection with the accompanying drawings in which:

FIG. 1 is perspective view of the a implement having a handle with a gelmedallion in accordance with the present invention;

FIG. 2 is a cross-sectional view through the line 2-2 of FIG. 1 showingthe preferred embodiment of the present invention;

FIG. 3 is a cross-sectional view through the line 2-2 of FIG. 1 showingan alternative embodiment of the present invention; and

FIG. 4 is a cross-sectional view through the line 2-2 of FIG. 1 showinga further alternative embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to the creation of a handle 10 for tools,implements and objects, such as handles for toothbrushes and razors,that is softer to the touch than any previous design, and yet is durableand aesthetically pleasing and is rigid enough for exacting control bythe user. It should be understood that the construction of the presentinvention is shown and described in connection with a toothbrush andrazor handle 10 by way of example for ease of discussion andillustration. Any type of tool, implement or object can take advantageof the construction of the present invention.

Turning first to FIG. 1, the invention includes an implement 2, such asa razor or toothbrush with a handle construction 10 containing a numberof elements. First, a rigid shaped core 12 of plastic or metal providesstructure and shape of the implement 2. One or more areas or“medallions” or members, generally referred to as 14, with a moldedurethane, silicone or other polymer gel 16 of preferably less than 65shore 00 durometer is also provided. One cushioning member 14 is shown,by way of example.

As can be seen in FIG. 2, preferably, the cushioning member 14 islocated within a recess 18 formed in the rigid core 12 of the handleimplement 2. A thin outer layer 20, such as an elastomeric polymercoating or elastomeric film covers the top surface 16 a of the moldedcushioning gel 16.

Optionally, this outer layer 20 can contain antimicrobial agents such assilver, copper and zinc. More specifically, nano-particle metals,including silver, copper and zinc, can be used as the antimicrobialagents, such as those manufactured by the Nano-Horizons Company. Theouter layer 20, such as the film or polymer coating, can optionallycontain antimicrobial agents to control the growth of bacteria. Byhaving these antimicrobial agents in the top surface layer 20 only, theycan be used very economically in small quantities and yet still behighly functional since they are on the entire surface. In oneembodiment, an Omniflex 18411 film containing silver active agents canbe employed as an antimicrobial. It is also possible to use awater-based polyurethane coating as layer 20 with silver antimicrobialadditive. Other non-silver based antimicrobial agents can also be usedin the top film or coating layer 20.

In addition, the outer layer 20 may contain phase change materials thatcan make the surface feel cool to the touch. Such phase change materialscan be added to the outer layer 20, namely, a surface film orelastomeric surface coating. The addition of phase change materials suchas phase change containing microspheres sold under the brand name of“Outlast” can create the sensation of coolness for the user as theyabsorb body heat. The Outlast material consists of small spheres filledwith wax type materials that melt between 75 and 95 degrees F., which isjust below body temperature. As these materials melt, they absorb heat.Because of the thin outer layer 20 in the present invention, these phasechange materials can be added in small quantities and yet be present onthe surface of the implement 2 to come in direct contact with the userof the implement 2. The construction of the present invention is thuswell suited to deliver the benefits of these phase change materials inan economical way.

Optionally, the cushioning member 14, made of gel 16, can sit on a lowerbase layer 22, that may be any material, such as fabric, film, ornonwoven providing for stability. For example, FIGS. 2-4 illustratevarious embodiments of the present invention employing this multilayerconstruction. This lower layer 22 of fabric, film, or nonwoven materialcan additionally be printed or colored to provide additional aesthetics.

In FIG. 2, it is preferred that the cushioning member 14, made of gelmaterial 16, resides within a recess seat 18 of the rigid core member12. The lower layer 22 resides therebetween. However, it is alsopossible that the rigid core 12 can be molded or shaped to partially orfully contain the molded cushioning member 14, of the gel material 16,can extend entirely outside of the rigid core 12. In FIG. 3, the gelmember 16 includes a flange 24 while the lower layer also includes aflange 26. These flanges 24, 26 extend outwardly for encapsulation bythe rigid core member 12. In this example, it is preferred that therigid core member 12 molded to encapsulate the flanges 24, 26 of the gelmaterial 16 and lower layer 22. As a result, the gel member 16 and lowerlayer 22 are fixedly secured to the rigid core 12. FIG. 4 further showsthat all layers, namely, the gel material 16, top surface finish layer20 and lower layer 22 all emanate outwardly to provide respectiveflanges 24, 26 and 28 for encapsulation during the molding or formationprocess. It is also possible that this flange can be locked in bysnapping together two “clamshell” pieces rather than during the moldingor formation of the rigid core. If a line were to be drawn on thediagram showing that the rigid core is two snapped-together pieceslocking in the flange, this might show a more likely typical use. Also,another embodiment is possible where just the lower layer 26 is theflange, and neither the gel nor the top layer are locked in.

The rigid core 12 and the gel member 16 act together to provide bothstability and comfort to the user. It should be understood that eachlayer can be molded and formed using different methods and ofappropriate varying thicknesses and shapes to achieve the best comfortand aesthetics for a given application.

It has been found that a molded gel member 16 with a durometer of lessthan 65 shore 00 is preferred. More generally, a preferred range for thehardness of the gel member 16 for aesthetics and durability of thehandle is between 25 shore 00 and 60 shore 00. However, a gel material16 having a hardness greater or less than this range can also be used.One preferred embodiment of the invention uses a polyurethane gel with adurometer of 50-55 shore 00.

The gel member 16 may optionally be finished with a top layer 20. Thistop layer 20 may be in many different forms. For example, the top layer20, as seen in FIGS. 2-4, may be a film, such as an elastomeric filmwith a preferred thickness of less than 4 mil. Generally, for the topfinish layer 20, it is desirable to have a film less than 2 mil thick toprovide for the best combination of softness and durability. In somecases, films of up to 4 mil in thickness may be necessary to passcertain puncture or bite specifications. It has been found that for manyuses a polyurethane film with a thickness of between 0.4 mil and 1.0 milworks very well. Greater thickness provides for less softness but moredurability. The top finish layer 20 is preferably an elastomeric film sothat it can move with the gel. Non-elastomeric films, although they canbe used, are not as desirable because they will feel hard even over avery soft gel member. In one embodiment of the invention, a style 184110.75 mil film manufactured by Omniflex LLC of Greenfield, Mass. has beenused with good results.

As an alternative to the outer surface layer 20 being a film covering,the gel material 16 can be coated with a thin layer of elastomericpolymer coating. In accordance with the present invention, a water-basedpolyurethane top coating 20 is employed, but other elastomeric coatingscan be used including other types of water based coatings, 100% solidscoatings and solvent based coatings.

The outer finish layer 20 provides for encapsulation of the molded lowdurometer gel material 16, so that there is an aesthetically pleasingpoint of contact for the user. Either the elastomeric surface film orthe polymer top-coating can be pigmented, printed up or transparentdepending on the desired aesthetics.

Because the gel material 16 in the present invention is extremely soft,it is sometimes undesirable to have the edge 16 b of the molded gel 16flush with the more rigid plastic. This can create a sharp or hardfeeling at the transition point between the gel member 16 and the recessseat 18 of the more rigid core member 12. This is generally not aproblem in the prior art, because the prior art uses higher durometermaterials that are not so dramatically softer than the surroundingmaterials. In the present invention, because of the use of very lowdurometer gel materials 16, it is often desirable to have the edges 16 bof molded gel material 16 raised above the top edge 12 a of the rigidcore member 12 as seen in the cross-sectional views in FIGS. 2-4. Inthis way, the user is not exposed to a hard edge at the transitionpoint.

It has also been found that it is often desirable to have a lower layerof material 22, such as a film, fabric or nonwoven material bonded tothe underside of the gel member 16 for the purpose of adding stabilityand durability to the gel member 16. In accordance with the presentinvention, a polyester film in a thickness of 2 mil may be employed forthis purpose. It has also been found that many fabrics (both knitted andwoven) can work well in adding stability to the product. Also, anonwoven material can be used in this lower layer 22.

In addition to stabilizing the product, it has also been found that aclear or tinted molded gel material 16 transmits the aesthetics of thelower layer 22, in the form of a fabric, film, or nonwoven materialpositioned therebelow. Thus it is often desirable to have a colored orprinted film or fabric beneath the gel member 16 for aesthetic purposes.It has been found that printed polyester films, or dyed or printedfabrics or nonwovens can all work well in this regard for the lowerlayer 22. In accordance with the present invention, a printed knittedpolyester fabric beneath the gel material 16 can be used, for example.Also, for example, a printed polyester film beneath the gel member 16may be used. In each case, the surface aesthetics of the gel member 16takes on the color or printing of the lower layer 22 disposedtherebelow. The addition of this printed or colored lower layer cangreatly contribute to the aesthetics of the finished implement 2,namely, a toothbrush or razor, and the like.

The present invention allows for a novel integration of materials forany type of tool, implement or object, such as the handle 10 for atoothbrush or razor, providing for a softer feel not found in the priorart. The ability to further enhance the aesthetics by providing graphicsthat show through the gel material 16 is an advance over the prior art.Further, the addition of surface antimicrobial materials or phase changematerials to a cushioning gel member 16 in a handle 10 createsadditional advantages unseen in any prior art.

It would be appreciated by those skilled in the art that various changesand modifications can be made to the illustrated embodiments withoutdeparting from the spirit of the present invention. All suchmodifications and changes are intended to be within the scope of thepresent invention.

1. An improved handle, comprising: a rigid core defining a recess seattherein having a top edge; a molded gel member, having an outer surface,residing in the recess seat; and an outer layer disposed on the outersurface of the molded gel member.
 2. The improved handle of claim 1,wherein the core is manufactured of material selected from the groupconsisting of plastic and metal.
 3. The improved handle of claim 1,wherein the outer layer is selected from the group consisting of anelastomeric film layer and an elastomeric polymer coating.
 4. Theimproved handle of claim 1, wherein the outer layer is made ofpolyurethane.
 5. The improved handle of claim 1, wherein the gel memberis made of a material selected from the group consisting of polyurethaneand silicone-based material.
 6. The improved handle of claim 1, whereinthe outer layer is less than 4 mil in thickness.
 7. The improved handleof claim 1, wherein the outer layer is less than 2 mil in thickness. 8.The improved handle of claim 1, wherein the outer layer is less than 1mil in thickness.
 9. The improved handle of claim 1, wherein the outerlayer has a thickness in the range of 0.4 to 0.8 mil.
 10. The improvedhandle of claim 1, wherein the outer layer is pigmented.
 11. Theimproved handle of claim 1, wherein the outer layer is transparent. 12.The improved handle of claim 1, wherein the outer layer of film carriesprinted graphics on a surface thereof in communication with the moldedgel member thereon.
 13. The improved handle of claim 1, wherein theouter layer contains antimicrobial agents.
 14. The improved handle ofclaim 13, wherein the outer layer contains antimicrobial agents selectedfrom the group consisting of antimicrobial silver, antimicrobial copperand antimicrobial zinc.
 15. The improved handle of claim 13, wherein theouter layer contains antimicrobial agents selected from the groupconsisting of nano-particle silver, nano-particle copper andnano-particle zinc.
 16. The improved handle of claim 1, wherein themolded gel member is not flush with the top edge of the recess seat ofthe hard plastic core.
 17. The improved handle of claim 1, furthercomprising: a lower layer between the gel and the recess seat.
 18. Theimproved handle of claim 17, wherein the lower layer is a polyesterfilm.
 19. The improved handle of claim 18, wherein the lower layer ofpolyester film is 2 mil or less.
 20. The improved handle of claim 17,wherein the lower layer is fabric.
 21. The improved handle of claim 20,wherein the fabric is nonwoven.
 22. The improved handle of claim 17,wherein the lower layer is colored.
 23. The improved handle of claim 17,wherein the lower layer carries printing thereon.
 24. The improvedhandle of claim 1, further comprising: a surface finish disposed on thetop of the outer layer.
 25. The improved handle of claim 24, wherein thesurface finish contains antimicrobial agents.
 26. The improved handle ofclaim 1, wherein the outer layer contains phase change materials. 27.The improved handle of claim 26, wherein the phase change materials arecontained in microshperes.
 28. The improved handle of claim 24, whereinthe surface finish contains phase change materials.
 29. The improvedhandle of claim 1, wherein the gel member is removably secured to therecess seat.
 30. The improved handle of claim 1, wherein the gel memberhas a durometer of 65 shore 00 or less.
 31. The improved handle of claim1, wherein the gel member has a durometer of 55 shore 00 or less. 32.The improved handle of claim 1, wherein the gel member has a durometerof 45 shore 00 or less.
 33. The improved handle of claim 1, wherein thegel member has a durometer of 25 shore 00 to 55 shore
 00. 34. Theimproved handle of claim 1, wherein the molded gel member includes aflange embraced by the rigid core.
 35. The improved handle of claim 1,wherein the molded gel member and the outer layer both includerespective flanges embraced by the rigid core.
 36. The improved handleof claim 17, wherein the molded gel member, the outer layer and thelower layer each include respective flanges embraced by the rigid core.